US20060115622A1 - Method of making a ribbed part out of thermoplastic material covered in a conductive foil, and a ribbed part - Google Patents
Method of making a ribbed part out of thermoplastic material covered in a conductive foil, and a ribbed part Download PDFInfo
- Publication number
- US20060115622A1 US20060115622A1 US11/271,319 US27131905A US2006115622A1 US 20060115622 A1 US20060115622 A1 US 20060115622A1 US 27131905 A US27131905 A US 27131905A US 2006115622 A1 US2006115622 A1 US 2006115622A1
- Authority
- US
- United States
- Prior art keywords
- foil
- thermoplastic material
- rib
- opening
- orifice
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000011888 foil Substances 0.000 title claims abstract description 62
- 239000012815 thermoplastic material Substances 0.000 title claims abstract description 34
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 4
- 238000000034 method Methods 0.000 claims abstract description 19
- 239000012530 fluid Substances 0.000 claims abstract description 6
- 238000000151 deposition Methods 0.000 claims abstract description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 9
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- 239000006096 absorbing agent Substances 0.000 claims description 2
- 239000004020 conductor Substances 0.000 claims description 2
- 230000002787 reinforcement Effects 0.000 claims description 2
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14836—Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14336—Coating a portion of the article, e.g. the edge of the article
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24174—Structurally defined web or sheet [e.g., overall dimension, etc.] including sheet or component perpendicular to plane of web or sheet
Definitions
- Automobile manufacturers seek to make use of the huge outside surface constituted by the bodywork of a vehicle to provide radiating elements such as a sensor or an antenna.
- an electrically conductive foil e.g. made of aluminum
- thermoplastic material in order to obtain a bumper skin or a fairing that includes a radiating element.
- Aluminum foil is used having thickness of less than 0.1 millimeters (mm), e.g. foodgrade aluminum foil having thickness substantially equal to 0.07 mm.
- the term aluminum “foil” is generally used when the thickness is less than 0.15 mm, whereas the term aluminum “sheet” is used when the thickness is greater than 0.15 mm.
- the overmolding is conventionally performed by depositing an electrically conductive foil on an inside surface of a mold defining the shape of the skin or of the fairing.
- the conductive foil needs to be located on the inside face of the part.
- those two bodywork parts generally do not include ribs.
- thermoplastic material is quite flexible, it is not unusual for such a part to need to be stiffened by ribs located on its inside surface.
- the mold for the part conventionally includes a blind orifice opening out into the face of the mold that defines the inside face of the part.
- the blind orifice would be covered by the conductive foil placed on the face of the mold that defines the inside surface of the part.
- thermoplastic material would then be injected into the mold under pressure.
- the thermoplastic material would spread throughout the mold and in particular into the blind orifice, such that under the effect of the pressure it would tear the conductive foil covering the orifice. Because it is so fine, such foil cannot withstand the pressure of the thermoplastic material, unlike a sheet or a plate which is stronger.
- thermoplastic part would then be obtained that is covered in a conductive foil that is locally interrupted at the rib.
- the electrical conduction of the conductive foil would then be interrupted at the rib.
- thermoplastic material is molded initially, and then it is covered in a conductive foil, taking care to ensure that the foil covers the ribs.
- That method increases the quantities of conductive material used but without improving the performance of the sensor or the antenna.
- the action of laying the conductive foil is complicated by the angles constituted by the rib.
- the method requires the dimensions of the mold used to be modified in order to allow for the thickness of the sheet, and such modification is not required with overmolding techniques.
- the invention seeks to propose a method of obtaining a ribbed part made of thermoplastic material and covered in a conductive foil that does not present any of the above-mentioned drawbacks.
- An electrically conductive one-piece foil having thickness of less than 0.1 mm is deposited on an inside surface of a mold defining the shape of the part in such a manner as to cover at least in part a blind orifice of the mold opening out into the inside surface and defining the shape of a rib.
- At least one orifice opening is formed in the foil, the opening being shaped in such a manner as to allow fluid thermoplastic material to pass through the opening, and to allow the foil to remain in one piece.
- the mold is filled with fluid thermoplastic material.
- the present inventors have found that providing the openings are large enough, then the mold can be filled with the thermoplastic material without tearing the foil.
- the foil thus remains in a single piece once the final part has been obtained, and electrical conduction is ensured over the entire surface of the foil.
- the resulting thermoplastic material part has an outside surface and at least one rib projecting from the surface, the base of the rib being substantially elongate and extending in a longitudinal direction.
- the outside surface is covered by a one-piece electrically conductive foil of thickness less than 0.1 mm and comprising, firstly two portions situated on either side of the base of the rib, and secondly at least one bridge of material crossing the base of the rib in a substantially transverse direction.
- the mold is filled by injecting molten thermoplastic material.
- the molten thermoplastic material is injected close to the rib. In this way, it is possible to control more accurately the pressure of the thermoplastic material in the vicinity of the rib.
- a step of compressing the mold is also implemented.
- the opening is made by perforating the foil.
- the perforations in the foil are regularly spaced over the opening of the orifice.
- the regular spacing makes it possible to ensure that a bridge of material between two perforations is not subjected to excessive pressure that might cause it to give way.
- the surface area of the opening is at least 10 square millimeters (mm 2 ) so as to allow the thermoplastic material to flow therethrough.
- the orifice opening formed in the foil is shaped in such a manner that the foil covers the orifice at least in part.
- the orifice opening provided in the foil is shaped in such a manner that the surface area of the zone of the orifice that is covered by the foil is greater than the surface area of the zone of the orifice that is not covered by the foil. That makes it possible to minimize the disturbances in the electrical conductivity of the foil generated by the opening formed in the foil.
- the part forms any of the parts of a motor vehicle taken from the set constituted by at least a bumper skin, a skin reinforcement, an impact absorber, a fender liner, a fairing, a deflector, a front panel, a spoiler, a tailgate and its frame, a roof, a hood, a rearview mirror, and a wheel arch.
- the foil is made of aluminum.
- FIGS. 1 to 6 An embodiment of the invention is described with reference to FIGS. 1 to 6 which do not present any limiting character with respect to the scope of the invention.
- FIG. 1 is a perspective view of a ribbed thermoplastic beam in accordance with the invention.
- FIG. 2 is a partially cutaway view of the FIG. 1 beam showing the bridges of conductive foil material crossing the base of the rib.
- FIG. 3 is a perspective view of a mold portion used for obtaining the beam of FIG. 1 .
- FIG. 4 is a view in cross-section of the FIG. 3 mold.
- FIG. 5 is a view similar to FIG. 4 , taken through the rib.
- FIG. 6 is a view in longitudinal section of the FIG. 3 mold.
- Reference Explanation 10a and 10b Portions constituting the mold 10.
- 24 Duct for injecting thermoplastic material into the mold.
- the ducts 24 are placed in register with cavities 12.
- the mold used is conventional. It operates either by injection or by injection and compression.
- the perforations 14 are obtained in conventional manner by means of a punch.
- thermoplastic material 24 injected into the mold tends to fill it completely.
- the thermoplastic material 24 passes through the perforations 14 to fill the cavity 12 .
- the thermoplastic material does not tear the bridges 22 , so the electrical connection between the portions 4 a and 4 b of the foil 4 is conserved.
Abstract
Description
- Parts made of thermoplastic material covered on the surface in an electrically conductive foil, and including at least one rib.
- Automobile manufacturers seek to make use of the huge outside surface constituted by the bodywork of a vehicle to provide radiating elements such as a sensor or an antenna. For this purpose, it is known to overmold an electrically conductive foil, e.g. made of aluminum, in thermoplastic material in order to obtain a bumper skin or a fairing that includes a radiating element. Aluminum foil is used having thickness of less than 0.1 millimeters (mm), e.g. foodgrade aluminum foil having thickness substantially equal to 0.07 mm. The term aluminum “foil” is generally used when the thickness is less than 0.15 mm, whereas the term aluminum “sheet” is used when the thickness is greater than 0.15 mm.
- The overmolding is conventionally performed by depositing an electrically conductive foil on an inside surface of a mold defining the shape of the skin or of the fairing. For reasons of appearance and in order to protect the radiating element, the conductive foil needs to be located on the inside face of the part. However those two bodywork parts generally do not include ribs.
- Given that a bodywork part made of thermoplastic material is quite flexible, it is not unusual for such a part to need to be stiffened by ribs located on its inside surface.
- However the known method of overmolding the aluminum foil cannot be used for a part that has ribs on its inside face.
- In order to obtain a part having a rib on its inside face, the mold for the part conventionally includes a blind orifice opening out into the face of the mold that defines the inside face of the part.
- If it is desired to make a ribbed part covered in a conductive foil by using the same method as is used for making a part that is not ribbed, then the blind orifice would be covered by the conductive foil placed on the face of the mold that defines the inside surface of the part.
- Thermoplastic material would then be injected into the mold under pressure. The thermoplastic material would spread throughout the mold and in particular into the blind orifice, such that under the effect of the pressure it would tear the conductive foil covering the orifice. Because it is so fine, such foil cannot withstand the pressure of the thermoplastic material, unlike a sheet or a plate which is stronger.
- A thermoplastic part would then be obtained that is covered in a conductive foil that is locally interrupted at the rib. The electrical conduction of the conductive foil would then be interrupted at the rib.
- Consequently, overmolding is not appropriate for fabricating a ribbed part covered in a conductive foil. That is why that method has until now been considered unsuitable by the person skilled in the art.
- Since conventional overmolding on a conductive foil cannot be performed when making a part that is ribbed, it is possible to use a different method in which the conductive foil is put into place subsequently. The part of thermoplastic material is molded initially, and then it is covered in a conductive foil, taking care to ensure that the foil covers the ribs.
- That method increases the quantities of conductive material used but without improving the performance of the sensor or the antenna. In addition, the action of laying the conductive foil is complicated by the angles constituted by the rib. Furthermore the method requires the dimensions of the mold used to be modified in order to allow for the thickness of the sheet, and such modification is not required with overmolding techniques.
- The known method of fabricating a ribbed part out of thermoplastic material that is covered in a conductive foil thus presents numerous drawbacks.
- The invention seeks to propose a method of obtaining a ribbed part made of thermoplastic material and covered in a conductive foil that does not present any of the above-mentioned drawbacks.
- An electrically conductive one-piece foil having thickness of less than 0.1 mm is deposited on an inside surface of a mold defining the shape of the part in such a manner as to cover at least in part a blind orifice of the mold opening out into the inside surface and defining the shape of a rib.
- At least one orifice opening is formed in the foil, the opening being shaped in such a manner as to allow fluid thermoplastic material to pass through the opening, and to allow the foil to remain in one piece.
- The mold is filled with fluid thermoplastic material.
- The present inventors have found that providing the openings are large enough, then the mold can be filled with the thermoplastic material without tearing the foil. The foil thus remains in a single piece once the final part has been obtained, and electrical conduction is ensured over the entire surface of the foil.
- The resulting thermoplastic material part has an outside surface and at least one rib projecting from the surface, the base of the rib being substantially elongate and extending in a longitudinal direction. In addition, the outside surface is covered by a one-piece electrically conductive foil of thickness less than 0.1 mm and comprising, firstly two portions situated on either side of the base of the rib, and secondly at least one bridge of material crossing the base of the rib in a substantially transverse direction.
- The mold is filled by injecting molten thermoplastic material.
- The molten thermoplastic material is injected close to the rib. In this way, it is possible to control more accurately the pressure of the thermoplastic material in the vicinity of the rib.
- A step of compressing the mold is also implemented.
- The opening is made by perforating the foil.
- The perforations in the foil are regularly spaced over the opening of the orifice. The regular spacing makes it possible to ensure that a bridge of material between two perforations is not subjected to excessive pressure that might cause it to give way.
- The surface area of the opening is at least 10 square millimeters (mm2) so as to allow the thermoplastic material to flow therethrough.
- The orifice opening formed in the foil is shaped in such a manner that the foil covers the orifice at least in part.
- The orifice opening provided in the foil is shaped in such a manner that the surface area of the zone of the orifice that is covered by the foil is greater than the surface area of the zone of the orifice that is not covered by the foil. That makes it possible to minimize the disturbances in the electrical conductivity of the foil generated by the opening formed in the foil.
- The part forms any of the parts of a motor vehicle taken from the set constituted by at least a bumper skin, a skin reinforcement, an impact absorber, a fender liner, a fairing, a deflector, a front panel, a spoiler, a tailgate and its frame, a roof, a hood, a rearview mirror, and a wheel arch.
- The foil is made of aluminum.
- An embodiment of the invention is described with reference to FIGS. 1 to 6 which do not present any limiting character with respect to the scope of the invention.
-
FIG. 1 is a perspective view of a ribbed thermoplastic beam in accordance with the invention. -
FIG. 2 is a partially cutaway view of theFIG. 1 beam showing the bridges of conductive foil material crossing the base of the rib. -
FIG. 3 is a perspective view of a mold portion used for obtaining the beam ofFIG. 1 . -
FIG. 4 is a view in cross-section of theFIG. 3 mold. -
FIG. 5 is a view similar toFIG. 4 , taken through the rib. -
FIG. 6 is a view in longitudinal section of theFIG. 3 mold. -
Reference in the Of the embodiment drawings Part Beam 2 Foil Aluminum foil 4 Rib Rib 6 Inside surface Inside surface 8 Mold Mold 10 Orifice Cavity 12 Opening Hole, perforation 14 Thermoplastic material Thermoplastic material 16 Outside surface Outside surface 18 Base of rib Base of rib 20 Portions Portions 4a and 4b Bridges Bridges 22 -
Reference Explanation 10a and 10b Portions constituting the mold 10.24 Duct for injecting thermoplastic material into the mold. Preferably, and as shown in FIGS. 5 and 6 , theducts 24are placed in register with cavities 12.10 The mold used is conventional. It operates either by injection or by injection and compression. 14 The perforations 14 are obtained in conventional mannerby means of a punch. - The
thermoplastic material 24 injected into the mold tends to fill it completely. In particular, thethermoplastic material 24 passes through theperforations 14 to fill thecavity 12. Providing the rate of injection is not too high, the thermoplastic material does not tear thebridges 22, so the electrical connection between theportions foil 4 is conserved.
Claims (15)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR0411988A FR2877601B1 (en) | 2004-11-10 | 2004-11-10 | PROCESS FOR PRODUCING A RIBBED THERMOPLASTIC MATERIAL COVERED WITH A CONDUCTIVE SHEET, RIBBED PIECE |
FR0411988 | 2004-11-10 |
Publications (2)
Publication Number | Publication Date |
---|---|
US20060115622A1 true US20060115622A1 (en) | 2006-06-01 |
US7320771B2 US7320771B2 (en) | 2008-01-22 |
Family
ID=34953094
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/271,319 Active US7320771B2 (en) | 2004-11-10 | 2005-11-10 | Method of making a ribbed part out of thermoplastic material covered in a conductive foil, and a ribbed part |
Country Status (3)
Country | Link |
---|---|
US (1) | US7320771B2 (en) |
EP (1) | EP1657045A1 (en) |
FR (1) | FR2877601B1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE1027720B1 (en) * | 2019-10-30 | 2021-05-31 | Del Ponti Bv | Holder with carrier for fence |
US11577789B2 (en) | 2018-07-26 | 2023-02-14 | Sabic Global Technologies B.V. | Vehicle component comprising metal insert and strut component |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2974533B1 (en) * | 2011-04-29 | 2014-07-04 | Faurecia Interieur Ind | METHOD FOR MOLDING A PLASTIC ELEMENT COMPRISING AN INSERT AND PLASTIC ELEMENT THEREFOR |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4584767A (en) * | 1984-07-16 | 1986-04-29 | Gregory Vernon C | In-mold process for fabrication of molded plastic printed circuit boards |
US5824253A (en) * | 1994-05-18 | 1998-10-20 | Don De Cristo Concrete Accessories, Inc. | Method for molding a protective cover for an exposed end of a bar |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR1414582A (en) * | 1963-11-28 | 1965-10-15 | Linnepe & Schiffer Fa | Multilayer wall workpiece |
FR2349441A1 (en) * | 1976-04-29 | 1977-11-25 | Voisin & Pascal Carton | Bonding of cast or moulded fitting onto panel - by cutting and stamping panel to form opening with lips |
ES8704381A1 (en) * | 1986-05-15 | 1987-04-01 | Castella Llorca Juan M | Pack with integral label and projection |
JPS63162209A (en) * | 1986-12-26 | 1988-07-05 | Ricoh Co Ltd | Production of resin box with shielding plate |
JPH01184113A (en) * | 1988-01-18 | 1989-07-21 | Matsushita Electric Ind Co Ltd | Monolithic molding of resin and film |
JPH0462119A (en) * | 1990-06-26 | 1992-02-27 | Furukawa Electric Co Ltd:The | Preparation of resin molding with electrically conductive layer |
JPH05124060A (en) * | 1991-11-07 | 1993-05-21 | Fujitsu Ltd | Resin molded form and manufacture thereof |
JP3073163B2 (en) * | 1996-07-31 | 2000-08-07 | 株式会社ピーエフユー | Electronic device housing and method of manufacturing the same |
JP3925242B2 (en) * | 2002-02-28 | 2007-06-06 | 日産自動車株式会社 | Resin molded product and its insert molding method |
-
2004
- 2004-11-10 FR FR0411988A patent/FR2877601B1/en not_active Expired - Fee Related
-
2005
- 2005-11-10 US US11/271,319 patent/US7320771B2/en active Active
- 2005-11-10 EP EP05292394A patent/EP1657045A1/en not_active Withdrawn
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4584767A (en) * | 1984-07-16 | 1986-04-29 | Gregory Vernon C | In-mold process for fabrication of molded plastic printed circuit boards |
US5824253A (en) * | 1994-05-18 | 1998-10-20 | Don De Cristo Concrete Accessories, Inc. | Method for molding a protective cover for an exposed end of a bar |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11577789B2 (en) | 2018-07-26 | 2023-02-14 | Sabic Global Technologies B.V. | Vehicle component comprising metal insert and strut component |
BE1027720B1 (en) * | 2019-10-30 | 2021-05-31 | Del Ponti Bv | Holder with carrier for fence |
Also Published As
Publication number | Publication date |
---|---|
FR2877601B1 (en) | 2008-07-04 |
FR2877601A1 (en) | 2006-05-12 |
EP1657045A1 (en) | 2006-05-17 |
US7320771B2 (en) | 2008-01-22 |
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